System and method for providing a reflective insulation layer

ABSTRACT

A reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer having first perforations, an intermediate low emittance layer having first perforations and an outer synthetic polymer layer having second perforations. Additionally, the reflective insulation layer includes a first expander spaced between the low emittance layer and the intermediate low emittance layer, to couple the low emittance layer to the intermediate low emittance layer and form a first air space. Additionally, the reflective insulation layer includes a second expander spaced between the intermediate low emittance layer and the outer synthetic polymer layer, to couple the intermediate low emittance layer to the outer synthetic polymer layer and form a second air space.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional Application that claims the benefit ofU.S. Non-Provisional patent application Ser. No. 12/503,493, filed Jul.15, 2009 and U.S. Provisional Patent Application No. 61/080,719, filedJul. 15, 2008, which are both incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to insulation layers, and moreparticularly, to a system and method for providing reflective insulationlayers.

Thermal insulation is an important characteristic of most residential,commercial, agricultural, and industrial building structures, includingresidences. Conventional thermal insulation systems include reflectiveinsulation technology, which attempts to reflect heat energy back to theatmosphere and/or not emit heat energy into a structure during thesummer. Additionally, this conventional reflective insulation technologyattempts to reflect heat energy back into the structure and/or not emitheat energy into the atmosphere during the winter. For example, theassignee of the present application designed a reflective insulationlayer including a metallic foil layer, a paper layer, and a paperexpander integral with the paper layer, which couples the metallic foillayer and the paper layer.

However, conventional reflective insulation systems have severalshortcomings. For example, conventional reflective insulation systemsinclude cellulose, a material which, in the presence of moisture, canfacilitate the growth of mold. Additionally, the layers of conventionalreflective insulation systems do not structurally accommodate vaportransmission, without perforations through all the layers.

Accordingly, it would be advantageous to provide a system for providinga reflective insulation system which does not facilitate the growth ofmold and further provides vapor transmission to all of the layers of thereflective insulation system.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment of the present invention, a reflective insulationlayer is provided for a structure. The structure has a wall and aplurality of spaced-apart strips extending along the wall from a topportion of the wall to a bottom portion of the wall. The reflectiveinsulation layer includes a low emittance layer, an intermediate lowemittance layer and an outer synthetic polymer layer. The reflectiveinsulation layer also includes a pair of first expanders spaced betweenthe low emittance layer and the intermediate low emittance layer to forma first air space between the low emittance layer and the intermediatelow emittance layer. The reflective insulation layer also includes apair of second expanders spaced between the intermediate low emittancelayer and the outer synthetic polymer layer to form a second air spacebetween the intermediate low emittance layer and the outer syntheticpolymer layer.

In another embodiment of the present invention, a reflective insulationlayer is provided, for the structure. The reflective insulation layerincludes a low emittance layer with first perforations, an intermediatelow emittance layer with first perforations, and an outer syntheticpolymer layer with second perforations. The reflective insulation layeralso includes a first expander spaced between the low emittance layerand the intermediate low emittance layer, to couple the low emittancelayer to the intermediate low emittance layer and to form a first airspace between the low emittance layer and the intermediate low emittancelayer. The reflective insulation layer also includes a second expanderspaced between the intermediate low emittance layer and the outersynthetic polymer layer, to couple the intermediate low emittance layerto the outer synthetic polymer layer and to form a second air spacebetween the intermediate low emittance layer and the outer syntheticpolymer layer.

In another embodiment of the present invention, a method is presentedfor providing reflective insulation for the structure. The methodincludes forming a reflective insulation layer, with the steps offorming first perforations in a low emittance layer, forming firstperforations in an intermediate low emittance layer, and forming secondperforations in an outer synthetic polymer layer. The method alsoincludes the step of extending a first expander between the lowemittance layer and the intermediate low emittance layer, to couple thelow emittance layer to the intermediate low emittance layer and to forma first air space between the low emittance layer and the intermediatelow emittance layer. The method also includes the step of extending asecond expander between the intermediate low emittance layer and theouter synthetic polymer layer, to couple the intermediate low emittancelayer to the outer synthetic polymer layer and to form a second airspace between the intermediate low emittance layer and the outersynthetic polymer layer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of the invention briefly described abovewill be rendered by reference to specific embodiments thereof that areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the embodiments of theinvention will be described and explained with additional specificityand detail through the use of the accompanying drawings in which:

FIG. 1 is a plan view of an exemplary embodiment of a system forproviding a reflective insulation layer according to the presentinvention;

FIG. 2 is a top view of an exemplary embodiment of the system forproviding a reflective insulation layer illustrated in FIG. 1;

FIG. 3 is a top view of an exemplary embodiment of a system forproviding a reflective insulation layer according to the presentinvention;

FIG. 4 is a flow chart illustrating an exemplary embodiment of a methodfor providing a reflective insulation layer according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

In describing particular features of different embodiments of thepresent invention, number references will be utilized in relation to thefigures accompanying the specification. Similar or identical numberreferences in different figures may be utilized to indicate similar oridentical components among different embodiments of the presentinvention.

FIG. 1 illustrates a reflective insulation layer 10 for a structure 12.The structure 12 includes a wall 14 with a plurality of horizontallyspaced-apart strips (or vertically oriented) 16,18 and vertically spacedapart strips (or horizontally oriented) 20,22. The horizontallyspaced-apart strips 16,18 extend along the wall 14 from a top portion 24of the wall 14 to a bottom portion 26 of the wall 14. In an exemplaryembodiment, the horizontally spaced-apart strips 16,18 and/or verticallyspaced-apart strips may be spaced by 16″ or 24″, as appreciated by oneof skill in the art. Although FIG. 1 illustrates that the wall 14includes the horizontally spaced-apart strips 16,18 and the verticallyspaced-apart strips 20,22, in the embodiments of the present invention,the wall need not be formed with horizontally spaced-apart strips andvertically spaced-apart strips, and may be formed from either thehorizontally spaced-apart strips or the vertically spaced-apart strips,with any spacing. Additionally, although FIG. 1 illustrates that thehorizontally spaced-apart strips 16,18 extend from the top portion 24 tothe bottom portion 26 of the wall 14, the horizontally spaced apartstrips need not extend the entire length of the wall.

FIG. 2 illustrates the reflective insulation layer 10 upon installationto the wall 14 of the structure 12. Although the exemplary embodiment ofFIG. 2 illustrates a block wall, the reflective insulation layer 10 maybe similarly installed on a frame wall, for example, as appreciated byone of skill in the art. The reflective insulation layer 10 includes alow emittance layer 28, which tends to reflect radiation energy and/ornot emit radiation energy, for example, having a plurality of firstperforations 30, and a synthetic polymer layer 32 having a plurality ofsecond perforations 34. Although the low emittance layer 28 may beformed from aluminum foil, the low emittance layer 28 may be formed fromany metalized material. In an exemplary embodiment, the firstperforations 30 may have a spatial density of approximately ⅜″ or 0.04inches square pattern or a pattern and size that would produce a permrating of at least 5 per ASTM E96, water vapor permeance standard, asappreciated by one of skill in the art. In another exemplary embodiment,the second perforations 34 may have a spatial density of ⅜″ or 0.04inches square pattern or a pattern and size that would produce a permrating of at least 5 per ASTM E96, water vapor permeance standard, asappreciated by one of skill in the art. However, one or both of theperforations 30,34 may have a spatial density of any square pattern,linear pattern, or a random pattern, for example.

Additionally, the reflective insulation layer 10 includes an expander 36which is spaced between the low emittance layer 28 and the syntheticpolymer layer 32, and is configured to couple the low emittance layer 28to the synthetic polymer layer 32 to form a first reflective air space38 between the low emittance layer 28 and the synthetic polymer layer32. The expander 36 is coupled to respective inner surfaces 40,42 of thelow emittance layer 28 and the synthetic polymer layer 32. Although FIG.2 illustrates that the expander 36 is positioned between the innersurfaces 40,42 toward the ends of the layers 28,32 and adjacent thehorizontally spaced-apart strips 16,18, the expander may be positionedat any location between the layers 28,32, provided that it couples theinner surfaces 40,42 together. In an exemplary embodiment, the expander36 is formed from a synthetic, non-paper material.

The first perforations 30 in the low emittance layer 28 and the secondperforations 34 in the synthetic polymer layer 32 are configured topermit vapor transmission through the respective low emittance layer 28and synthetic polymer layer 32. The synthetic polymer layer 32 is formedfrom a mold-resistant material, such as a material excluding celluloseto enhance a resistance to of the growth of mold. In an exemplaryembodiment of the present invention, a reflective insulation layer 10may achieve one or more of the following performance characteristics: nogrowth of mold & mildew in accordance with ASTM C1338, an approximate7.46 water vapor permeance in accordance with ASTM E96, an approximate<25 flame spread rating, an approximate <50 smoke developed rating, aclass A interior wall and ceiling finish classification in accordancewith ASTM E84; no corrosivity, no bleeding, and no delamination, inaccordance with ASTM D3310; and an approximate 0.034 foil emittance inaccordance with ASTM C1371, for example. The numeric performancecharacteristics listed above are merely exemplary, and the syntheticpolymer layer of the present invention may be formed from amold-resistant material which deviates from these numeric performancecharacteristics, yet still achieves an acceptable level of moldresistance.

As illustrated in FIG. 1, the reflective insulation layer 10 has a width33 dimensioned with the plurality of horizontally spaced apart strips16,18 or vertically spaced apart strips 20,22, depending on theorientation of the reflective insulation layer 10. For example, thereflective insulation layer 10 secured to horizontally spaced apartstrips 16,18 is rotated 90 degrees from the reflective insulation layer10 secured to vertically spaced apart strips 20,22. As previouslydiscussed, although the wall 14 of FIG. 1 has both horizontallyspaced-apart strips 16,18 and vertically spaced-apart strips 20,22, thewall may have either horizontally spaced apart strips or verticallyspaced-apart strips, and thus the reflective insulation layer would beoriented in the manner described herein, based on the individualconfiguration of the strips of each particular wall. The width 33 of thereflective insulation layer 10 is dimensioned with the plurality ofspaced apart strips 16,18 such that an opposing first and second side44,46 of the respective reflective insulation layer 10 is secured alonga respective first and second strip 16,18, where the first and secondstrips 16,18 are consecutively spaced apart along the wall. Uponsecuring the respective reflective insulation layer 10 to the first andsecond strips 16,18, the expander 36 is configured to form the firstreflective air space 38 and a second reflective air space 52 (FIG. 2)between the wall 14 and the low emittance layer 28. The first and secondreflective air spaces 38,52 are configured to restrict air movementwithin a cavity 53 defined by the first strip 16, the second strip 18,the reflective insulation layer 10 and the wall 14, where therestriction of air movement within the cavity 53 reduces a passage ofheat flow by convection through the cavity 53. The low emittance layer28 is configured to reflect or not emit radiation from passing into thecavity 53 to reduce a passage of heat flow by radiation through thecavity. In an exemplary embodiment, an R value (a unit of measurement ofthermal resistance) of the reflective insulation layer is a valuebetween 4.1 and 5.1, based on the thickness of the strips 16,18. As withthe previously discussed numerical performance characteristics, thereflective insulation layer may have an R value which deviates from thenumerical value listed above, and still effectively reduces a passage ofheat flow through the cavity.

In securing the first and second side 44,46 of the reflective insulationlayer 10 to the respective first and second strip 16,18, the reflectiveinsulation layer 10 is oriented with the synthetic polymer layer 32facing an opposite direction to the wall 14 and the low emittance layer28 facing the wall 14. The first side 44 is attached along the firststrip 16 from the top portion 24 to the bottom portion 26 of the wall14. The reflective insulation layer 10 is severed across the width 33adjacent to the bottom portion 26 of the wall 14. The reflectiveinsulation layer 10 is stretched across the width 33 between the firstand second strip 16,18, upon which the second side 46 is attached alongthe second strip 18 from the top portion 24 to the bottom portion 26.Additionally, a top end 54 and a bottom end 56 of the reflectiveinsulation layer 10 opposite to the top end of the reflective insulationlayer are respectively attached, such as with staples, screws, or anadhesive, to a top strip and a bottom strip, the top strip and bottomstrips are configured to intersect the spaced apart strips respectivelyadjacent to the top portion and the bottom portion of the wall.

FIG. 3 illustrates an additional embodiment of a reflective insulationlayer 10′ including a low emittance layer 28′, such as an aluminum foilor metalized material, including a metalized polymer, for example; anintermediate low emittance layer 29′ such as an aluminum foil ormaterial with metallic deposits; and an outer synthetic polymer layer32′ In an exemplary embodiment of the present invention, the outersynthetic polymer layer 32′ may have one or more of the followingperformance characteristics: an approximate weight of 81±10% GSM usingthe ASTM D 3776-96 method, an approximate M.D. tensile strength of250±20% N/2.5 cm using the ASTM D 5034-90 method, an approximate C.D.tensile strength of 205±20% N/2.5 cm using the ASTM D 5034-90 method, anM.D. elongation of 90±20% using the ASTM D 5034-90 method, and a C.D.elongation of 95±20% using the ASTM D 5034-90 method. As with thepreviously discussed numerical performance characteristics, the outerlayer of the additional embodiment illustrated in FIG. 3 may have aperformance characteristic which deviates from the numerical performancecharacteristics listed above.

The reflective insulation layer 10′ includes a first expander 36′ spacedbetween the low emittance layer 28′ and the intermediate low emittancelayer 29′ to form a first reflective air space 38′ between the lowemittance layer 28′ and the intermediate low emittance layer 29′. In anexemplary embodiment of the present invention, the first expander 36′with a 48 gauge (0.00001″ units) may have one or more of the followingperformance characteristics: an approximate nominal yield of 41,200in²/lb, approximate MD and TD F-5 respective values of 15,900 lb/in²,and 14,600 lb/in², approximate MD and TD tensile strengths at break of39,800 lb/in² and 36,300 lb/in², approximate MD and TD elongation atbreak values of 120% and 129%, approximate MD and TD heat shrinkage at190° C. of 3.7% and 0.4%, approximate A-side and B-side coefficient offriction values of 0.40 and 0.30 and an approximate haze value of 2.1%.As with the previously discussed numerical performance characteristics,the first expander 36′ may have a performance characteristic whichdeviates from the numerical performance characteristics listed above.

Additionally, the reflective insulation layer 10′ includes a secondexpander 37′ between the intermediate low emittance layer 29′ and theouter synthetic polymer layer 32′ to form a second reflective air space53′ between the intermediate low emittance layer 29′ and the outersynthetic polymer layer 32′. Upon securing the respective reflectiveinsulation layer 10′ to the first and second strips 16′,18′, the firstexpander 36′ forms the first reflective air space 38′ and a thirdreflective air space 52′ between the wall 14′ and the low emittancelayer 28′. Additionally, the second expander 37′ forms the secondreflective air space 53′ upon securing the reflective insulation layer10′ to the first and second strips 16′,18′. In an exemplary embodimentof the present invention, a reflective insulation layer 10′ may achieveone or more of the following performance characteristics: no growth ofmold & mildew in accordance with ASTM C1338, an approximate 7.46 watervapor permeance in accordance with ASTM E96, an approximate <25 flamespread rating, an approximate <50 smoke developed rating, a class Ainterior wall and ceiling finish classification in accordance with ASTME84; no corrosivity, no bleeding, and no delamination, in accordancewith ASTM D3310; and an approximate 0.034 foil emittance in accordancewith ASTM C1371, for example. Those elements of FIG. 3 not discussedherein, are similar to those elements discussed above, without primenotation, and require no further discussion herein. As with thepreviously discussed numerical performance characteristics, thereflective insulation layer 10′ may have a performance characteristicwhich deviates from the numerical performance characteristics listedabove. Additionally, in an exemplary embodiment, the first and secondexpanders 36′, 37′ may be formed from a synthetic, non-paper material.

FIG. 4 illustrates an exemplary embodiment of a method 100 for providingreflective insulation for a structure 12. The method 100 begins at block101, by forming 102 a reflective insulation layer 10. The forming 102step includes forming 104 a first plurality of perforations 30 in a lowemittance layer 28, and forming 106 a second plurality of perforations34 in a synthetic polymer layer 32. Additionally, forming 102 thereflective insulation layer 10 includes spacing 108 an expander 36between the low emittance layer 28 and the synthetic polymer layer 32,where the expander 36 couples the low emittance layer 28 to thesynthetic polymer layer 32 to form a first reflective air space 38between the low emittance layer 28 and the synthetic polymer layer 32.In an alternate method, a plurality of perforations may be formed in anadditional low emittance layer, and the additional low emittance layermay be spaced from the low emittance layer with an additional expander.

This written description uses examples to disclose embodiments of theinvention, including the best mode, and also to enable any personskilled in the art to make and use the embodiments of the invention. Thepatentable scope of the embodiments of the invention is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they have structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

That which is claimed is:
 1. A reflective insulation layer for astructure, said structure having a wall and a plurality of spaced-apartstrips extending along said wall from a top portion of the wall to abottom portion of the wall, said reflective insulation layer comprising:a low emittance layer; an intermediate low emittance layer ; an outersynthetic polymer layer; a pair of first expanders spaced between saidlow emittance layer and said intermediate low emittance layer to form afirst air space between said low emittance layer and said intermediatelow emittance layer; and a pair of second expanders spaced between saidintermediate low emittance layer and said outer synthetic polymer layerto form a second air space between said intermediate low emittance layerand said outer synthetic polymer layer.
 2. The reflective insulationlayer of claim 1, wherein upon securing said respective reflectiveinsulation layer to said strips, said pair of first expanders isconfigured to form said first air space and a third air space betweensaid wall and said low emittance layer.
 3. The reflective insulationlayer of claim 1, wherein the low emittance layer and the intermediatelow emittance layer are made from aluminum material.
 4. A reflectiveinsulation layer for a structure, said structure having a wall and aplurality of spaced-apart strips extending along said wall from a topportion of the wall to a bottom portion of the wall, said reflectiveinsulation layer comprising: a low emittance layer having a plurality offirst perforations; an intermediate low emittance layer having aplurality of first perforations; an outer synthetic polymer layer havinga plurality of second perforations; a first expander spaced between thelow emittance layer and the intermediate low emittance layer, said firstexpander configured to couple said low emittance layer to saidintermediate low emittance layer to form a first air space between saidlow emittance layer and said intermediate low emittance layer; and asecond expander spaced between the intermediate low emittance layer andthe outer synthetic polymer layer, said second expander configured tocouple said intermediate low emittance layer to said outer syntheticpolymer layer to form a second air space between said intermediate lowemittance layer and said outer synthetic polymer layer.
 5. Thereflective insulation layer of claim 4, wherein the first perforationsin the low emittance layer and the intermediate low emittance layer andthe second perforations in the outer synthetic polymer layer areconfigured to permit vapor transmission through the low emittance layer,the intermediate low emittance layer and synthetic polymer layer.
 6. Thereflective insulation layer of claim 4, wherein said first expander iscoupled to a respective inner surface of said low emittance layer andsaid intermediate low emittance layer and said second expander iscoupled to a respective inner surface of said intermediate low emittancelayer and said outer synthetic polymer layer.
 7. The reflectiveinsulation layer of claim 6, wherein said outer synthetic polymer layeris comprised of a mold-resistant material.
 8. The reflective insulationlayer of claim 7, wherein said mold-resistant material excludescellulose to enhance resistance to a growth of mold, and wherein saidlow emittance layer and said intermediate low emittance layer arealuminum foil layers.
 9. The reflective insulation layer of claim 3,wherein said reflective insulation layer has a width dimensioned withsaid plurality of spaced apart strips such that an opposing first andsecond side of said respective reflective insulation layer are securedalong a respective first and second strip, said first and second stripsbeing consecutively spaced apart along said wall.
 10. The reflectiveinsulation layer of claim 9, wherein upon securing said respectivereflective insulation layer to said first and second strips, said firstexpander and said second expander are configured to form said first airspace and a third air space between said wall and said low emittancelayer.
 11. The reflective insulation layer of claim 10, wherein saidfirst, second and third air spaces, or said low emittance layer,intermediate emittance layer and outer synthetic polymer layer areconfigured to restrict air movement within a cavity defined by saidfirst strip, said second strip, said reflective insulation layer andsaid wall, wherein said restriction of air movement within said cavitybeing provided to reduce a passage of heat flow by convection throughsaid cavity.
 12. The reflective insulation layer of claim 11, whereinsaid low emittance layer is configured to reflect radiation from passinginto said cavity to reduce a passage of heat flow by radiation throughsaid cavity.
 13. The reflective insulation layer of claim 9, wherein anR value of the reflective insulation layer is a value between 4.1 and5.1.
 14. The reflective insulation layer of claim 8, wherein uponsecuring said first and second side to said respective first and secondstrip: said first side is attached along said first strip from said topportion to said bottom portion of the wall; said reflective insulationlayer is severed adjacent to the bottom portion of the wall; and saidreflective insulation layer is stretched across the width between saidfirst and second strip, and said second side is attached along saidsecond strip from said top portion to said bottom portion.
 15. Thereflective insulation layer of claim 14, wherein upon securing saidfirst and second side to said respective first and second strip: a topend and bottom end opposite to said top end of said reflectiveinsulation layer are respectively attached to a top strip and a bottomstrip, said top strip and bottom strips are configured to intersect saidspaced apart strips respectively adjacent to said top portion and saidbottom portion of said wall.
 16. A method for providing reflectiveinsulation for a structure, said structure having a wall and a pluralityof spaced-apart strips extending along said wall from a top portion ofthe wall to a bottom portion of the wall, said method comprising:forming a reflective insulation layer, comprising; forming a firstplurality of perforations in a low emittance layer, forming a firstplurality of perforations in an intermediate low emittance layer,forming a second plurality of perforations in an outer synthetic polymerlayer, and extending a first expander between the low emittance layerand the intermediate low emittance layer, said first expander configuredto couple said low emittance layer to said intermediate low emittancelayer to form a first air space between said low emittance layer andsaid intermediate low emittance layer; and extending a second expanderbetween the intermediate low emittance layer and the outer syntheticpolymer layer, said second expander configured to couple saidintermediate low emittance layer to said outer synthetic polymer layerto form a second air space between said intermediate low emittance layerand said outer synthetic polymer layer.
 17. The method of claim 16,further comprising: installing said reflective insulation layerincluding a first side and a second side opposite to the first sidealong said wall, said spaced-apart strips including a first and secondstrip being consecutively spaced apart along said wall, said installingcomprising: attaching said first side of said reflective insulationlayer along said first strip from said top portion to said bottomportion of the wall; severing said reflective insulation layer adjacentto said bottom portion of the wall; stretching said reflectiveinsulation layer across said width from the first strip to the secondstrip; and attaching said second side of said reflective insulationlayer along said second strip from said top portion to said bottomportion of the wall
 18. The method of claim 17, wherein said reflectiveinsulation layer further includes a top end and a bottom end opposite tothe top end, said installing further comprising: attaching said top endand bottom end of said reflective insulation layer along a respectivetop strip and bottom strip, said top strip and bottom strip intersectingsaid spaced apart strips respectively adjacent to said top portion andsaid bottom portion of said wall.